Fluid catalytic cracking catalyst

ABSTRACT

An active alumina composite and a cracking catalyst comprising the composite useful in hydrocarbon conversion processes. The composite and catalyst are particularly useful in fluid catalytic cracking processes, wherein sulfur-containing feedstock is subjected to catalytic conversion at a temperature in the range of about 800° F. to about 1300° F. in the presence of the catalyst which becomes sulfided during the conversion reaction and thereafter the catalyst is subjected to regeneration by burning sulfur-containing coke from the catalyst with an oxygen-containing gas at a temperature within the range of about 800° to 1500° F. The novel catalyst composition comprises 90 to 99 weight percent cracking catalyst and 1 to 10 weight percent of a composite of alumina and bismuth oxides containing 0.05 to 25 weight percent bismuth, calculated as the metal. This catalyst composition has the ability to remove sulfur oxides from gases to a greater extent than catalyst compositions comprising cracking catalyst and active alumina. The composition may comprise also platinum or a platinum group metal as a carbon monoxide combustion promoter.

This application is a division, of application Ser. No. 180,357, filed Aug. 22, 1980 now U.S. Pat. No. 4,344,926.

The present invention relates to a process for fluid catalytic cracking of a hydrocarbon feedstock containing sulfur compounds. In one of its more specific aspects this invention relates to a process for removing gaseous sulfur compounds comprising sulfur oxides from gaseous mixtures in the presence of free oxygen with a particulate solid which comprises alumina in association with bismuth. In one of its more particular aspects, the invention relates to a method for the recovery of sulfur from an alumina-sulfur complex comprising bismuth by contacting said complex with hydrogen to form hydrogen sulfide.

It has been proposed heretofore to utilize alumina in particulate form as a vehicle for the removal of sulfur from gases containing sulfur oxides by forming a solid compound containing aluminum atoms and sulfur atoms and then contacting the solid compound with a hydrocarbon at a temperature of about 800° to 1300° F. to form hydrogen sulfide. The present invention represents an improvement over such processes. It has now been discovered that a composition comprising bismuth and alumina is more effective for the removal of sulfur oxides from gaseous mixtures than alumina alone or alumina in admixture with precious metal catalysts.

The removal of sulfur compounds from sulfur-containing gases by reaction with various solids including limestone, dolomite, and alumina are well known. The use of active particulate alumina for sulfur removal in a fluidized catalytic cracking unit has been disclosed in U.S. Pat. No. 4,071,436, wherein particulate alumina is physically admixed with a particulate cracking catalyst. The alumina reacts with sulfur oxides in the catalyst regeneration zone to form a solid compound containing sulfur, which, in turn, reacts with products of cracking in the fluidized catalytic cracking zone to form hydrogen sulfide. Hydrogen sulfide is discharged from the fluid catalytic cracking zone with the products of the catalytic cracking reaction and may be separated from the FCC products.

It has also been proposed heretofore, in U.S. Pat. Nos. 4,115,250 and 4,115,251, to provide a precious metal oxidation catalyst in admixture with a zeolite type cracking catalyst in a fluid bed catalytic cracking system for the removal of sulfur oxides from flue gases in the regeneration zone of a fluidized catalytic cracking unit. We have now found that an alumina-bismuth composition forming a part of the present invention is more effective for the removal of sulfur oxides from waste gases, such as flue gases from the regeneration zone of a fluidized catalytic cracking unit, than either active alumina, per se, or active alumina in combination with a carbon monoxide combustion promoter when employed in combination with a cracking catalyst consisting essentially of an amorphous silica-alumina matrix and a crystalline aluminosilicate zeolite.

The present invention relates to a process for removing sulfur oxides from gaseous mixtures containing oxides of sulfur by contacting said gaseous mixtures containing sulfur oxides at an elevated temperature and in the presence of free oxygen with a composition comprising alumina and bismuth at a temperature above about 500° C. forming a composite comprising alumina, bismuth, and sulfur, and thereafter regenerating the composition by contacting the alumina-bismuth-sulfur composite with hydrogen, optionally admixed with hydrocarbons, at an elevated temperature, above about 400° C., with the production of gaseous hydrogen sulfide.

One specific embodiment of the present invention comprises a fluid catalytic cracking process in which a composition of alumina and bismuth, preferably a composition comprising at least 90 weight percent active alumina and 0.1 to 10 weight percent bismuth is physically admixed in particulate form with particulate fluidized cracking catalyst, e.g. a Y zeolite in a silica-alumina matrix, and the resulting solids mixture circulated in a fluidized catalytic cracking unit. The solids mixture circulates in the fluidized bed catalytic cracking system from the cracking zone to the regeneration zone and back to the cracking zone. In the regeneration zone, the alumina-bismuth composition effects removal of gaseous sulfur compounds from the regeneration gas stream to form a composite comprising alumina, bismuth and sulfur, while in the cracking zone, the sulfur in the sulfur-alumina-bismuth composite reacts with hydrogen produced during cracking of hydrocarbons in the cracking zone to form hydrogen sulfide. The function of the alumina-bismuth composition is to capture sulfur from the gases present in the regenerator, carry the sulfur back into the cracking zone, and then convert the sulfur into hydrogen sulfide. Thus, the flue gases leaving the catalyst regenerator are cleaned up by the removal of sulfur compounds therefrom before they are discharged to the atmosphere and the sulfur values recovered as hydrogen sulfide in the catalytic cracking reactor. Hydrogen sulfide may be readily recovered in the usual processing facilities employed for the separation and treatment of products of catalytic cracking from sulfur-containing charge stocks.

The present invention represents an improvement over prior art processes employing alumina for this purpose n that the composition of alumina and bismuth of this invention is more active with respect to removal of sulfur oxides from gaseous mixtures than is alumina alone.

A carbon monoxide combustion promoter may be also included in the physical mixture of solids employed in a fluid catalytic cracking system. A number of suitable carbon monoxide combustion promoters are known in the art and are disclosed, for example, in U.S. Pat. No. 4,115,251. Such carbon monoxide combustion promoters are generally useful in fluid catalytic cracking processes and may be used in conjunction with the alumina-bismuth compositions of this invention.

In one of its broader aspects, the present invention comprises a process for the removal of a gaseous sulfur compound from a mixture of gases comprising sulfur oxides and free oxygen which comprises contacting said mixture of gases with a composite of alumina and bismuth.

The bismuth-alumina composition of the present invention is prepared by the formation of a cojel of alumina and a soluble bismuth salt, e.g. bismuth nitrate, followed by drying of the gel, and crushing and sizing the dried gel, which may be further dried and calcined at 1000° to 1200° F. to produce a bismuth oxide-alumina composition in accordance with the present invention.

In a preferred embodiment of the process of this invention, a composite mixture of particulate solids comprising 1 to 10 weight percent of a composition of alumina and bismuth oxide, as described herein, and 90 to 99 weight-percent of a particulate zeolite cracking catalyst, comprising a Y zeolite in an alumina matrix, is employed in a fluidized bed catalytic cracking unit as described hereinabove. The bismuth-alumina composition may comprise 0.05 to 25 weight percent bismuth and 75 to 99.95 weight percent alumina. A preferred composition comprises 0.5 to 1 weight percent bismuth as the oxide on gamma alumina, which in a preferred embodiment of this invention is admixed with a Y zeolite cracking catalyst in relative proportions of about 10 weight percent bismuth oxide-alumina composition and 90 weight percent zeolite cracking catalyst.

EXAMPLES

A number of test runs were made to determine the effectiveness of the composition of the present invention for the removal of sulfur oxides in the regeneration of a commercial catalytic cracking catalyst contaminated with coke containing sulfur. The cracking catalyst employed in all of these tests was used catalyst taken from a commercial fluid catalystic cracking unit. The catalyst was comprised primarily of a product of Davison Chemical Division of W. R. Grace & Co., sold under the tradename "CBZ-1" as a high activity cracking catalyst comprising a Y-type synthetic crystalline zeolite in an amorphous alumina matrix. Physical properties of the catalyst as indicated by laboratry tests are reported in Table I.

                  TABLE I                                                          ______________________________________                                         CRACKING CATALYST                                                              Tests Results                                                                  ______________________________________                                         Surface Area, m.sup.2 /gm                                                                          105                                                        Pore Volume cc/gm   0.37                                                       Density, lb/ft.sup.3                                                           Aerated             47.6                                                       Settled             51.8                                                       Particle Size Distribution, wt. %                                               0-20μ           0                                                          20-40μ           0                                                          40-80μ           22                                                         80+μ             78                                                         Average Particle Size, μ                                                                        86                                                         Alumina Content, wt. %                                                                             37.7                                                       Sodium Content, wt. %                                                                              0.41                                                       X-Ray Metals, wppm*                                                            Cu                  10                                                         Ni                  220                                                        Fe                  3330                                                       Cr                  310                                                        V                   370                                                        Zeolite Content, wt. %                                                                             7.9                                                        ______________________________________                                          *parts per million by weight                                             

EXAMPLE 1

The cracking catalyst of Table I was tested in a reactor under typical catalytic cracking operating conditions in which a synthetic high sulfur gas oil containing 2.0 weight percent sulfur was made up of 90.6 wt.% dodecane, 1.0 wt.% hexene-1 and 8.4 wt.% benzothiophene, and subjected to catalytic cracking in a micro-reactor. Several test runs were conducted for each example and the data averaged to provide a basis for judging the effectiveness of various additives to the system to effect sulfur removal by capturing sulfur oxides from the regenerator flue gases. The runs were carried out at a cracking reaction temperature of 920° F. with a catalyst to oil ratio of 3:1 in a fixed bed reaction zone. The resulting catalyst, contaminated with coke containing sulfur, was regenerated with air in a fluidized bed regeneration zone at a temperature of 1240° F. Results of these tests are shown in Example 1 of Table IV.

EXAMPLE 2

The cracking catalyst of Example 1 was admixed with 10 percent by weight of gamma alumina produced by calcining a high purity alpha alumina monohydrate marketed by Conoco Chemicals Division, Continental Oil Company, under the tradename "Catapal SB". The alpha alumina monohydrate was converted to gamma alumina by calcining for three hours at 900° F. Properties of the alpha and gamma aluminas are indicated in Table II. This mixture was tested in 15 runs under conditions comparable to those of Example 1, and the data averaged. Results of these tests are shown in Example 2 of Table IV.

                  TABLE II                                                         ______________________________________                                         Alumina content*, wt. %                                                                           75%                                                         Loss on Ignition, wt. %                                                                           25%                                                         Carbon*, wt. %     0.3%                                                        SiO.sub.2 *, wt. % 0.008%                                                      Fe.sub.2 O.sub.3 *, wt. %                                                                         0.005%                                                      Na.sub.2 O*, wt. % 0.004%                                                      Sulfur*, wt. %     0.01%                                                       Crystal Structure* α-alumina monohydrate                                 Crystal Structure**                                                                               γ-alumina                                             Surface Area (BET)**                                                                              250 m.sup.2 /g                                              Pore Volume**                                                                  0-100 A            0.49 cc/gm                                                  0-10,000 A         0.53 cc/gm                                                  Loose Bulk Density*                                                                               43 lb/ft.sup.3                                              Particle Size Distribution*                                                                       48% < 45μ                                                                   11% > 90μ                                                ______________________________________                                          *As received.                                                                  **After calcination for 3 hrs. at 900° F.                         

EXAMPLE 3-5

Compositions containing 0.1, 0.5 and 1 percent bismuth on alumina were prepared and mixed with Table I cracking catalyst in relative proportions of 90 weight percent catalyst and 10 weight percent bismuth oxide-alumina composition and tested under conditions comparable to those of Example 1. Several tests runs were made with each of these compositions and the test data averaged. The averaged results of these tests are reported in Examples 3-5, respectively, of Table IV.

In a preferred method of preparation of the composition of Example 5, 2.3 grams Bi(NO₃)₃.5H₂ O were added to 100 milliliters distilled water after which 15 milliliters concentrated nitric acid were added to effect solution of the bismuth nitrate. The resulting solution was mixed into 132 grams of 60-200 mesh alpha alumina monohydrate of Table II to form a stiff gel. An additional 35 milliliters of distilled water were added to incorporate all of the powder into the gel. The resulting bismuth-alumina gel was air dried overnight at 300° F., crushed and sized to 60-200 mesh, then heated at 285° F. for one hour and at 1200° F. for two hours with stirring every half hour. The resulting composition contains 1 weight percent bismuth and 99 weight percent active alumina. This composition is then mixed with cracking catalyst of Table I in relative proportions of 90 weight percent catalyst and 10 weight percent bismuth-alumina composition, and tested under conditions comparable to those of Example 1. Test results are included in Example 5 of Table IV.

EXAMPLE 6

A four percent bismuth-alumina composition was prepared and admixed with cracking catalyst of Table I in relative proportions of 90 weight percent cracking catalyst and 10 weight percent of the alumina-bismuth oxide composition, tested in 12 test runs under conditions comparable to those of Example 1, and the test data averaged. The averaged results of these tests are shown in Table IV.

EXAMPLE 7

Cracking catalyst of Table I was admixed with 60-200 mesh gamma alumina of Table II in relative proportions of 90 weight percent cracking catalyst, 9.94 weight percent alumina, and 0.06 weight percent of a platinum on alumina combustion promoter marketed commercially by Filtrol Corporation under the tradename "Filtrox H". Physical properties of this material are shown in Table III. The purpose of this example was to determine whether the use of a carbon monoxide combustion promoter would have any advantageous or adverse effects on the removal of sulfur from catalyst regeneration off-gases by combination of sulfur oxides with alumina. Seven test runs were carried out with this combination of cracking catalyst, active alumina, and carbon monoxide combustion promoter under conditions comparable to those of Example 1. The averaged results of these tests are shown in Table IV.

                  TABLE III                                                        ______________________________________                                         CO COMBUSTION PROMOTER                                                         Description        Results                                                     ______________________________________                                         X-Ray Metals, wppm*                                                            Cu                 <10                                                         Ni                 40                                                          Fe                 4100                                                        Cr                 70                                                          V                  170                                                         Particle Size Distribution                                                      0-20μ          0                                                           20-40μ          12                                                          40-80μ          64                                                          80+μ            24                                                          Average particle size, μ                                                                       64                                                          Surface Area, m.sup.2 /gm                                                                         110                                                         Pore Volume, cc/gm 0.33                                                        Density, lb/ft.sup.3                                                           Aerated            50.4                                                        Compacted          58.8                                                        Alumina Content, wt. %                                                                            76.7                                                        Silica Content, wt. %                                                                             --                                                          Sodium Content, wt. %                                                                             0.09                                                        Platinum, wppm     2300                                                        ______________________________________                                          *parts per million by weight                                             

                                      TABLE IV                                     __________________________________________________________________________                              Sulfur Oxides (1)                                                                         Average (2)                                Example                                                                             Catalyst            (Wt. % Feed Sulfur)                                                                       % Decrease                                 __________________________________________________________________________     1    FCC Catalyst        4.2 ± 0.5                                                                              --                                         2    FCC Cat. 90%/Al.sub.2 O.sub.3 10%                                                                  1.6 ± 0.3                                                                              62                                         3    FCC Cat. 90%/(0.1% Bi + Al.sub.2 O.sub.3) 10%                                                      1.3 ± 0.2                                                                              69                                         4    FCC Cat. 90%/(0.5% Bi + Al.sub.2 O.sub.3) 10%                                                      1.1 ± 0.1                                                                              74                                         5    FCC Cat. 90%/(1% Bi + Al.sub.2 O.sub.3) 10%                                                        1.1 ± 0.2                                                                              74                                         6    FCC Cat. 90%/(4% Bi + Al.sub.2 O.sub.3) 10%                                                        1.4 ± 0.2                                                                              67                                         7    FCC Cat. 90%/Al.sub.2 O.sub.3 9.94%/CO                                                             1.6 ± 0.3                                                                              62                                              Combustion Promoter 0.06%                                                 __________________________________________________________________________      (1) Sulfur oxides in regenerator flue gas.                                     (2) Percentage decrease in sulfur oxides in regenerator flue gas.        

It will be evident from the foregoing examples that bismuth-alumina compositions of the present invention are more effective for the removal of sulfur oxides from gaseous mixtures than alumina alone or mixtures of alumina and precious metal carbon monoxide combustion promoters. 

We claim:
 1. A composition of matter as a component in catalytic cracking compositions which consists essentially of a composite of active alumina and 0.5 to 1 weight percent bismuth as bismuth oxide prepared by forming a cogel of active alumina and a soluble bismuth salt, drying said gel and calcining the resulting composite at a temperature in the range of 1000° to 1200° F. for at least one hour.
 2. A composition according to claim 1 wherein said composite contains from 0.1 to 10 weight percent bismuth.
 3. A composition according to claim 1 wherein said composite contains from 0.1 to 4 weight percent bismuth.
 4. A catalytic cracking catalyst composition comprising a major portion of a cracking catalyst composed of a crystalline zeolite in a supporting matrix in intimate admixture with a minor portion of a composite of bismuth oxide and active alumina, wherein said composite contains from 0.05 to 25 weight percent bismuth, calculated as the metal.
 5. A catalytic cracking catalyst according to claim 4 wherein said composition contains 90 weight percent of said cracking catalyst and 10 weight percent of said composite of active alumina and bismuth oxides.
 6. A catalytic cracking catalyst according to claim 5 wherein said composite of bismuth oxide and alumina contains from 0.1 to 4 weight percent bismuth.
 7. A catalytic cracking catalyst according to claim 5 wherein said composite contains 0.5 to 1 weight percent bismuth.
 8. A catalytic cracking catalyst according to claim 4 wherein the cracking catalyst composition comprises platinum or a platinum compound.
 9. A composition of matter as a component in catalytic cracking compositions consisting essentially of alumina and bismuth and containing 0.05 to 25 weight percent bismuth prepared by forming a cojel of alumina and a soluble bismuth salt, drying the gel and calcining the resulting composite at a temperature in the range of 1000° to 1200° F. for at least one hour.
 10. A composition of matter according to claim 9 wherein said cojel is prepared by dissolving alumina in a nitric acid solution of bismuth nitrate.
 11. A composition according to claim 9 wherein said calcined composite comprises 0.5 to 1 percent bismuth by weight. 